Systems and methods for coupling sections of an electronic device

ABSTRACT

This is directed to systems and methods for coupling sections of an electronic device together. Sections of an electronic device can be coupled together via “knuckles.” The particular shape and structure of the knuckles can be based on various design considerations. For example, in some embodiments each section can function as an individual antenna. In this case, the knuckles can be designed in order to provide electrical isolation between the sections, thus allowing proper operation of the antennas. For example, the knuckles can be formed from a dielectric material, etc. As another design example, the knuckles can be designed in order to provide increased strength in areas of high strain, and/or to counteract torsional twisting in areas of high impact. As yet another design example, the knuckle can be designed in a manner that is aesthetically pleasing or which otherwise meets cosmetic requirements.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation patent application of U.S. patentapplication Ser. No. 16/573,773, filed Sep. 17, 2019 and titled “Systemsand Methods for Coupling Sections of an Electronic Device,” which is acontinuation patent application of U.S. patent application Ser. No.15/892,320, filed Feb. 8, 2018 and titled “Systems and Methods forCoupling Sections of an Electronic Device,” U.S. Pat. No. 10,443,442,which is a continuation patent application of U.S. patent applicationSer. No. 14/323,566, filed Jul. 3, 2014 and titled “Systems and Methodsfor Coupling Sections of an Electronic Device,” now U.S. Pat. No.9,894,787, which is a continuation patent application of U.S. patentapplication Ser. No. 12/987,741, filed Jan. 10, 2011 and titled “Systemsand Methods for Coupling Sections of an Electronic Device,” now U.S.Pat. No. 8,772,650, the disclosures of which are hereby incorporated byreference herein in their entireties.

FIELD

Systems and methods are disclosed for coupling sections of an electronicdevice. In particular, components of an electronic device can beassembled from two or more sections, where these sections may be coupledtogether using knuckles.

BACKGROUND

A portable electronic device can be constructed using differentapproaches. In some cases, an electronic device can be constructed byassembling several components together. These “components” can includeexternal components that are combined to form a device enclosure (e.g.,a device “housing”), as well as internal components that may providestructural support or other functionality for the electronic device(e.g., the internal component could be a microchip). Based on the designof the electronic device, the components can be formed from any suitablematerial(s) such as metals, plastics, or any other materials.

In some cases, the various components of the electronic device canoperate as part of an electrical circuit. For example, a particularcomponent could serve as a resistor or as a capacitor to another part ofthe electronic device. As another example, a component can function aspart of an antenna assembly of the electronic device. If the componentis used in only a single electrical circuit, then the component may beconstructed from a single piece of conductive material. If the samecomponent, however, is used in several different electrical circuits,the component may need to be constructed from several “sections” ofconductive elements. In this case, however, it may be necessary toseparate each of the conductive sections with an insulating or othernonconductive material, in order to ensure that each section operates inits own electrical circuit correctly.

SUMMARY

This is directed to systems and methods for coupling sections of anelectronic device. In some embodiments, an electronic device can beformed from several components, such as an outer periphery componentand/or other components. The outer periphery component may provide ahousing structure for the electronic device by encircling the electronicdevice. In some cases, this outer periphery component can be assembledfrom two or more “sections.” Knuckles may then be used to couple thesesections together.

The shape and structure of the knuckles can be based on various designconsiderations. For example, in some embodiments each section of theouter periphery component can function as an individual antenna, or asany other suitable electric circuit component. In this case, theknuckles can be designed in order to provide electrical isolationbetween the sections. For example, the knuckles can be formed from adielectric material, can be designed to have minimum capacitancerequirements, and the like. As another design example, the knuckles canbe designed in order to provide increased strength in areas of highstrain, and/or to counteract torsional twisting in areas of high impact.As yet another design example, the knuckle can be designed in a mannerthat is aesthetically pleasing or which otherwise meets cosmeticrequirements.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features of the present invention, its nature andvarious advantages will be more apparent upon consideration of thefollowing detailed description, taken in conjunction with theaccompanying drawings in which:

FIG. 1 is a schematic view of an illustrative outer periphery componentconstructed by connecting several sections together in accordance withsome embodiments of the invention;

FIG. 2 is a schematic view of a portion of an illustrative electronicdevice component in accordance with some embodiments of the invention;

FIGS. 3A-3C are schematic top views of illustrative components thatinclude a knuckle in accordance with some embodiments of the invention;

FIG. 4 shows a schematic view of an illustrative outer peripherycomponent with knuckles in accordance with some embodiments of theinvention;

FIGS. 5A-5E show various schematic views of a particular knuckle designin accordance with one embodiment of the invention;

FIGS. 6A-6E show various schematic views of another particular knuckledesign in accordance with one embodiment of the invention; and

FIGS. 7A-7E show various schematic views of another particular knuckledesign in accordance with one embodiment of the invention.

DETAILED DESCRIPTION

An electronic device can include several components assembled togetherto form internal and/or external features of the electronic device. Forexample, one or more internal components (e.g., electrical circuitryand/or internal support structures) can be placed within externalcomponents (e.g., housing structures) to provide an electronic devicehaving desired functionality. As used herein, the term “component”refers to a distinct entity of an electronic device, such as aparticular electronic circuit (e.g., a microchip), a member forming thehousing of the electronic device (e.g., a backplate, an outer peripherycomponent, and the like), an internal support structure (e.g., amid-plate), and the like.

In some cases, a component can be manufactured by assembling andconnecting two or more different individual elements (i.e., “sections”)together. As used herein, the term “section” refers to an individualportion of a component, where that component may be formed from multiplesections. The various sections of the component may then be coupledtogether using a “knuckle.” Based on the desired functionality anddesign of the component and its sections, these knuckles can exhibit awide range of shapes and structures. For example, the knuckles caninclude structural designs that reinforce the knuckle at areas of highmechanical strain, that counteract twisting movements at areas of hightorsion, that interlock with the sections to provide enhanced couplingsupport between the sections, that provide electrical isolation betweenthe sections, and the like.

FIG. 1 shows a schematic view of an illustrative component of anelectronic device in accordance with some embodiments of the presentinvention. In particular, FIG. 1 shows outer periphery component 100that can be constructed by connecting several sections together, such assections 110, 120, and 130. Outer periphery component 100 can beconstructed to form an exterior, periphery surface for an electronicdevice. In particular, outer periphery component 100 can surround orwrap around some or all of the internal components (e.g., electroniccircuits, internal support structures, and the like) of the electronicdevice. In other words, outer periphery component 100 can define aninternal volume into which internal components can be placed. Forexample, outer periphery component 100 can wrap around the electronicdevice such that external surface 101 of outer periphery component 100defines a left surface 102, a right surface 104, a top surface 106, anda bottom surface 108 of the electronic device.

The thickness, length, height, and cross-section of outer peripherycomponent 100 can be selected based on any suitable criteria including,for example, based on structural requirements (e.g., stiffness orresistance to bending, compression, tension or torsion in particularorientations). In some embodiments, outer periphery component 100 canserve as a structural member to which other electronic device componentscan be mounted. Some of the structural integrity of outer peripherycomponent 100 can come from the closed shape that it defines (e.g.,outer periphery component 100 forms a loop, thus providing structuralintegrity).

Outer periphery component 100 can have any suitably shapedcross-section. For example, outer periphery component 100 can have asubstantially rectangular cross-section. Each corner of thesubstantially rectangular cross-section can be rounded in shape, thusforming a “spline.” As used herein, the term “spline” refers to arounded corner portion of an outer periphery component. In someembodiments, outer periphery component 100 can have a cross-section inany other suitable shape including, for example, a circular shape, anoval shape, a polygonal shape, or a curved shape. In some embodiments,the shape or size of the cross-section of outer periphery component 100can vary along the length or width of the electronic device (e.g., anhourglass shaped cross-section).

Outer periphery component 100 of the electronic device can beconstructed using any suitable process. In some embodiments, outerperiphery component 100 can be constructed by connecting section 110 andsection 120 together at interface 112, connecting section 120 andsection 130 together at interfaces 122, and connecting section 130 andsection 110 together at interface 132. Although outer peripherycomponent 100 is illustrated in FIG. 1 as being constructed from threesections, one skilled in the art could appreciate the outer peripherycomponent 100 could alternatively be formed from any suitable number oftwo or more sections, and that the interfaces between the sections maybe positioned at any location on outer periphery component 100. Based onwhere the interfaces are located, the sections of outer peripherycomponent 100 can have any suitable shape. For example, in FIG. 1 thesections are illustrated as having a large L-shaped section 110, smallL-shaped section 130, and U-shaped section 120.

Each section can be constructed individually and later assembled to formouter periphery component 100. For example, each section can beindividually constructed using one or more of stamping, machining,working, casting, or any combinations of these. In some embodiments, thematerials selected for sections 110, 120 and 130 can be conductive, thusallowing the sections to provide an electrical functionality for theelectronic device. For example, sections 110, 120, and/or 130 can beformed from a conductive material and may then serve as an antenna forthe electronic device.

To join the individual sections together, intermediate knuckles 114, 124and 134 can be placed within interfaces 112, 122, and 132, respectively.In some embodiments, each of the knuckles can be constructed from amaterial that can begin in a first state and may subsequently change toa second state. As an illustration, the knuckles can be constructed froma plastic that begins in a first, liquid state and then subsequentlychanges to a second, solid state. While in the liquid state, the plasticcan be allowed to flow into interfaces 112, 122, and 132. After flowinginto these interfaces, the plastic material may subsequently be allowedto harden into knuckles 114, 124 and 134 (e.g., the plastic material isallowed to change into the second, solid state). Upon changing into thesolid state, the plastic material may then bond together sections 110and 120, 120 and 130, and 130 and 110, respectively, thus forming asingle new component (e.g., outer periphery component 100).

In addition to a material that is allowed to change from a first to asecond state, any other suitable material or process can be used to formknuckles 114, 124 and 134. For example, the knuckles can include amechanical fastener, connector, clip, or other connector piece that isprefabricated and then inserted between the component's sections. Asanother example, in some cases, the knuckles can include an adhesivethat is used instead of or in addition to a mechanical fastener orconnector. For example, an adhesive layer can be placed between thesections being connected. The adhesive layer can be provided using anysuitable approach including, for example, as a liquid or paste adhesive,tape, heat-based adhesive, or combination of these. In some embodiments,an adhesive layer can have a reduced thickness or width (e.g., reducingthe space between the sections) to ensure that the sections are properlyconnected. This may be due to mechanical properties of the adhesive, asa thicker layer of the adhesive may have limited strength in bending,compression, peeling, or tension.

FIG. 2 is a schematic close-up view of an interface between two sectionsof a component. For example, FIG. 2 shows a partial view of component200 that can be constructed from first section 210 and second section212, which may then be coupled together by knuckle 220.

First and second sections 210 and 212 may each be constructed from thesame material, or may each be constructed from a different material. Forexample, first and second sections 210 and 212 can be constructed fromone or more of a metal material, a plastic material, a compositematerial, an organic material, or any combinations of these. In somecases, one or both of sections 210 and 212 can be constructed fromconductive materials (and thus be used as part of the circuitry withinthe electronic device, such as an antenna), but may need to beelectrically isolated from one another for proper functioning of devicecircuitry. In such cases, knuckle 220 can be constructed from aninsulating or dielectric material to prevent an electrical signal fromcrossing the gap between first section 210 and second section 212. Insome embodiments, knuckle 220 can be constructed from a combination ofconductive and insulating materials, where the insulating materials aredisposed between the conductive materials. Alternatively, one or moreconductive materials can be embedded within insulating materials.

Any suitable knuckle material and process can be used to connect knuckle220 between first section 210 and second section 212. For example, asdescribed above with regards to knuckles 114, 124, and 134 of FIG. 1, aknuckle material which changes from a first state to a second state canbe used. Such a knuckle material could include a liquid or a moldablesolid (e.g., a soft clay-like state) that can be placed between sections210 and 212 such that the knuckle material is shaped into a suitableknuckle. Once properly positioned between the first section 210 andsecond section 212 (e.g., filling the gap between the sections), theknuckle material can change to a second state in which the knucklematerial adheres to the sections and provides a structurally sound bond(e.g., a mechanical bond) between first section 210 and second section212.

During manufacturing of first section 210 and second section 212,variations or errors in the sections' shapes can occur due tomanufacturing tolerances etc. However, because the knuckle material canflow into any gap between the first section 210 and second section 212while in the first state, the knuckle material can absorb or erase thesevariations. This can beneficially result in component 200 beingconstructed with a higher precision than its individual sections 210 and212. In this manner, this approach can be forgiving of imperfections andother manufacturing artifacts along the exposed surface of first section210 and second section 212. In fact, the opposing surfaces of firstsection 210 and second section 212 may not need to have correspondingfeatures, as the opposing surfaces of the first and second sections maynot engage or need to be placed in close proximity (e.g., as wouldotherwise be required with an adhesive). Moreover, the knuckle materialcan readily flow around and into features of first section 210 andsecond section 212 (as described below), thus ensuring that the knucklematerial is securely locked into the first and second sections uponhardening.

Any suitable process can be used to place the knuckle material betweenfirst section 210 and second section 212, and any suitable process canbe used to change the knuckle material from the first state to thesecond state. In some embodiments, a “molding process” can be used inwhich the knuckle material is initially inserted in a liquid state andthen is subsequently hardened. For example, one or more of injectionmolding, compression molding, transfer molding, extrusion molding, blowmolding, thermoforming, vacuum forming, or rotomolding processes can beused. In this case, a “one shot” process can be used in which theknuckle material is inserted in a single step, and then independentlychanges to its second state. In other words, the knuckle can be formedin a single step (e.g., in “one shot”) without necessitating additionalsteps or manufacturing processes.

As another example, a brazing process can be used instead of or inaddition to a molding process. For example, a dielectric compositematerial can be brazed between first section 210 and second section 212.In one implementation, a composite material can be placed in a fixturebetween first section 210 and second section 212, and the compositematerial can be heated so that it melts and fills a region between thesections. For example, first section 210, second section 212 and thecomposite material can be placed in contact with a heated surface, thuscausing the composite material to heat and flow. The composite materialcan be cooled once it has filled the region between first section 210and second section 212, thus forming a secure bond between the compositematerial and the sections. Any suitable type of brazing can be usedincluding, for example, torch blazing, furnace brazing, braze welding,vacuum brazing, or dip brazing. Any suitable composite material can beused, such as, for example, plastic, rubber, organic composites,non-conductive metal alloys, any other suitable dielectric orinsulating, materials, or any combinations of these. Furthermore, thegeometry of features along internal surfaces of first section 210 andsecond section 212 can be selected and designed to enhance the brazedbond.

The sections connected by the knuckle can include any suitable featurefor improving the adhesion between the sections and the knuckle. FIGS.3A-3C show schematic top views of illustrative components includingfirst and second sections coupled by a knuckle in accordance with someembodiment of the invention. The first and second sections can includeany suitable feature for improving a bond with the knuckle. In someembodiments, the sections can include one or more internal features thatprovide an interlocking interface, or that increase the surface arearequired for adhering the knuckle to the first and second sections. Forexample, a section can include a curved internal feature (e.g., aspherical or cylindrical recess or protrusion) into or around whichmaterial from the knuckle can extend, thus increasing a surfacetension-based force. As another example, a section can include a featurehaving one or more openings, holes, hooks or other attributes that canengage a corresponding feature of the knuckle, once the knuckle hastransitioned to the second state (e.g., a hole in the first section intowhich a post of the knuckle can extend). In some embodiments, thesections can include locking features such as a recessed edge that formsa hook into which the knuckle material can flow.

Component 300 shown in FIG. 3A can be constructed by connecting firstsection 302 and second section 304 using knuckle 306. To improve theadhesion between first section 302 and knuckle 306, first section 302can include opening 308 within the body of first section 302. Similarly,second section 304 can include opening 310 within the body of secondsection 304. Openings 308 and 310 can be connected to the main body ofknuckle 306 via channels 309 and 311, respectively. These openings andchannels can have any suitable size or shape including, for example, ashape selected such that the channel is smaller than the opening. Thiscan ensure that the knuckle material which flows into the opening cannotpass back through the channel, and thus may improve the retentionabilities of knuckle 306. Openings 308 and 310 can have any suitableshape including, for example, a curved or angled cross-section, or avariable cross-section.

Component 320 shown in FIG. 3B can be constructed by connecting firstand second sections 322 and 324 using knuckle 326. To improve theadhesion of knuckle 326 to first section 322 and second section 324,knuckle 326 can include overflowing portions 328 extending beyond thecross-section of first section 322 and second section 324. This maycause overflowing portion 328 to come into contact with exposed outersurfaces of first section 322 and second section 324. Overflowingportions 328 can extend over any suitable surface of first section 322and second section 324 including, for example, over one or more of a topsurface, a bottom surface, a front surface, or a back surface, and/oralong only one of the first and second sections, or various combinationsof these.

Component 340 shown in FIG. 3C can be constructed by connecting firstsections 342 and second section 344 using knuckle 346. First sections342 and second section 344 can include openings 348 and 330, andchannels 349 and 331, respectively, as described above in connectionwith component 300. To allow openings 348 and 330 to extend through theentire height of first and second sections 342 and 344, whilemaintaining uniform and consistent external surfaces of the sections,the first and second sections can include chamfers 343 and 345,respectively, extending from a surface of the sections. For example, thechamfers can extend from an internal surface of first and secondsections 342 and 344, such that the chamfers extend within an internalvolume of an electronic device that includes component 340. Openings 348and 330 can extend through chamfers 343 and 345, respectively, insteadof or in addition to the main bodies of the sections 342 and 344.

FIG. 4 shows an illustrative schematic view of components of electronicdevice 400 in accordance with some embodiments. For example, FIG. 4shows an outer periphery component 402 encircling an inner component404. For example, inner component 404 could include a midplate or otherstructural support component of electronic device 400. Similar to outerperiphery component 100 of FIG. 1, outer periphery component 402 can beassembled together from various sections. In particular, outer peripherycomponent 402 is illustrated as being assembled from foursections—section 410, section 420, section 430, and section 440—however,one skilled in the art could appreciate that any other suitable numberor setup of section could be used to form outer periphery component 402.Outer periphery component 402 can also include four rounded corners(i.e., splines 450, 452, 454, and 456). As mentioned above, the term“spline” as used herein refers to a rounded corner portion of an outerperiphery component.

In some embodiment, each of sections 410, 420, 430, and 440 can beformed from a conductive material and can function as an antenna orother electric circuit component of electronic device 400. As anillustration, section 410 could function as a Bluetooth® antenna,section 420 could function as a WiFi antenna, and sections 430 and 440could function as a cellular telephone antenna (e.g., where section 430could service a particular frequency range and section 440 could servicea different frequency range).

Sections 410, 420, 430, and 440 can each be coupled to another sectionusing knuckles 412, 422, 432, and 442 (e.g., where knuckle 412 cancouple section 410 and 420 together, knuckle 422 can couple section 420and 430 together, and so forth). In order to electrically isolate thesections of outer periphery component 402 (e.g., in the case where eachsection functions as an antenna or other electric circuit component), insome cases knuckles 412, 422, 432, and/or 442 can be formed from adielectric or other isolating material.

In some cases, one or all of the knuckles can be included within thesplines of outer periphery component 402. For example, knuckles 412 and422 are illustrated in FIG. 4 as being positioned with the curves ofsplines 450 and 452, respectively. Similarly, although knuckles 432 and442 are not illustrated as being located directly within the curve of aspline, these knuckles are illustrated as being positioned significantlywithin the vicinity of splines 454 and 456, respectively. Although FIG.4 illustrates a particular number of knuckles located in a particularposition, one skilled in the art could appreciate that outer peripherycomponent 402 could alternatively include any suitable number ofknuckles, and any suitable number of these knuckles could be locatedwithin a spline and/or adjacent to a spline or within any other suitablelocation of outer periphery component 402. In particular, the sectionsand placement of knuckles within electronic device 400 can be determinedbased on the layout of internal components and/or other structuraldesign considerations of electronic device 400.

The particular shape and structure of a knuckle can be based uponvarious design considerations. For example, as mentioned above, in somecases the knuckle can provide for electrical isolation between sectionsof the outer periphery component. Thus, the knuckle can be designed inorder to meet certain, minimum capacitance requirements (e.g., where agreater amount of capacitance can result in greater electrical isolationbetween the component's sections). As a particular illustration, theknuckle can be designed to have an increased amount of surface area,thus increasing the capacitance between the adjacent sections.

As another exemplary design consideration, the knuckles can be designedin order to have an increased amount of material in areas of highstrain, thus reducing the chances of the knuckle breaking under stress.As yet another exemplary design consideration, the knuckle can bedesigned to counteract torsional twisting. For example, ribs can beincluded in the knuckles to increase the stability of the structure,thereby reducing the chances of torsional movement and breaking of theouter periphery component. Such ribs or other support may especially bebeneficial when the knuckles are located within a spline area of theouter periphery component. For example, if an electronic device isaccidentally dropped, the spline area may be especially vulnerable tobreakage due to the concentrated impact forces upon the corners of theelectronic device (e.g., in this case knuckles 412 and 422 of FIG. 4 maybe more vulnerable than knuckles 422 and 432 of FIG. 4). Thus, knucklescan be designed in a manner that counteracts such impact forces (e.g.,by adding ribs and/or providing a thickened middle portion).

As yet another exemplary design consideration, the knuckles can bedesigned in a manner that is aesthetically pleasing or that otherwisemeets cosmetic requirements. For example, the knuckle can be designed ina manner which hides some or all of the knuckle under the outerperiphery component, such that a user may only view the polished, outersurface of the electronic device. As another example, the knuckle can bedesigned such that it is flush with an outer surface of the outerperiphery component, such that the electronic device has a smoothsurface free of bumps or protrusions.

FIGS. 5A-5E show various views of a schematic of a particular design forknuckle 500 in accordance with one embodiment. For example, knuckle 500could correspond to a particular embodiment of one or more of theknuckles of electronic device 400 of FIG. 4. In particular, FIG. 5Ashows an isotropic view of knuckle 500, FIG. 5B shows a top view ofknuckle 500, FIG. 5C shows a cross-sectional view of knuckle 500 alongan x-y plane, FIG. 5D shows a side view of knuckle 500 from the insideof an electronic device, and FIG. 5E shows a cross-sectional view ofknuckle 500 along a y-z plane.

As shown in FIGS. 5A-5E, knuckle 500 can include various rib features,such as rib 510 and rib 512. Rib 510 may lock into a first section ofthe outer periphery component and rib 512 may lock into a second sectionof the outer periphery component, thereby coupling the first section andthe second section together. Rib 510 and 512 can be any suitable shape,such as cylindrical shape which extends substantially through the heightof the outer periphery component. Ribs 510 and 512 can have a diameterwhich is sufficiently large to provide a secure bonding with thesections, thereby providing stability and resisting torsional movementof the sections. Knuckle 500 can also include spine 514 extending alongthe height of the knuckle, thereby providing strength and stability forknuckle 500.

As shown in FIGS. 5A-5E, knuckle 500 can also include various “dovetail”features, such as dovetail 520 placed horizontally with regards toknuckle 500 (e.g., located in the x-y plane) and dovetail 530 placedvertically with regards to knuckle 500 (e.g., located in the z-y plane).Dovetails 520 and 530 may provide additional stability and support forknuckle 500, and moreover can increase the thickness of knuckle 500(e.g., thereby providing increased electrical isolation between thesections and/or increasing the mechanical stability of knuckle 500).

In some embodiments, knuckle 500 can be designed and positioned in aparticular manner based on other components within the electronicdevice. For example, FIG. 5B illustrates internal component 599 locatednear knuckle 500. Due to internal design constraints, it may not bepossible to move internal component 599 to a different position withinthe electronic device. Accordingly, knuckle 500 may instead be designedin a manner such that it does not encroach upon or otherwise adverselyaffect internal component 599. As another illustration, knuckle 500 canbe designed in a manner such that it provides structural support forinternal component 599. For example, internal component 599 isillustrated in FIG. 5B as resting against knuckle 500.

Knuckle 500 can also be designed such that is has a significantly largemiddle area, thus providing enhanced structural support for knuckle 500.For example, the x-y cross-sectional view of FIG. 5C shows middleportion 540 of knuckle 500. As illustrated by this viewpoint, knuckle500 has a relatively large cross-sectional middle portion 540.

Additionally, knuckle 500 can also be designed such that the resultingelectronic device is aesthetically pleasing. For example, any exposedouter surface of knuckle 500 can be designed such that they are flushwith an outer surface of the electronic device, such as surface 550(FIGS. 5B and 5C), surface 560 (FIGS. 5D and 5E), and surface 570 (FIGS.5D and 5E).

FIGS. 6A-6E show various views of a schematic of another exemplarydesign for a knuckle in accordance with one embodiment. For example,knuckle 600 could correspond to a particular embodiment of one or moreof the knuckles of electronic device 400 of FIG. 4. In particular, FIG.6A shows an isotropic view of knuckle 600, FIG. 6B shows a top view ofknuckle 600, FIG. 6C shows a cross-sectional view of knuckle 600 alongan x-y plane, FIG. 6D shows a side view of knuckle 600 from inside anelectronic device, and FIG. 6E shows a cross-sectional view of knuckle600 along a y-z plane.

Similar to knuckle 500 of FIGS. 5A-5E, knuckle 600 can include rib 610,rib 612, spine 614, dovetail 620, and middle portion 640. Also similarto knuckle 500 of FIGS. 5A-5E, knuckle 600 can include surfaces 650,660, and 670 that can be substantially flush with a surface of theelectronic device, thereby providing an aesthetically pleasing facadefor the electronic device. However, dissimilar to knuckle 500 of FIGS.5A-5E, knuckle 600 may include two instance of a vertical dovetail, suchas dovetails 630 and 632 (FIG. 6D). As described above with regards toFIGS. 5A-5E, knuckle 500 may be designed in a particular manner based oninner components of the electronic device, such as inner component 599.In other words, knuckle 500 may have only a single dovetail 530 in orderto avoid encroaching onto inner component 599. However, knuckle 600 ofFIGS. 6A-6E may instead by located in a portion of the electronic devicethat is not adjacent to any inner components. Accordingly, knuckle 600can have two vertical dovetails, dovetails 630 and 632. The additionalvertical dovetail can thus increase the mechanical stability of knuckle600 by providing symmetric stability around the knuckle's axis.Additionally, each of dovetails 630 and 632 may lock into a differentsection of an outer periphery component; thus, the two instance ofdovetail 630 and 632 can help ensure that each of these sections aresecurely coupled to knuckle 600.

FIGS. 7A-7E show various views of a schematic of another exemplarydesign for a knuckle in accordance with one embodiment. For example,knuckle 700 could correspond to a particular embodiment of one or moreof the knuckles of electronic device 400 of FIG. 4. In particular, FIG.7A shows an isotropic view of knuckle 700, FIG. 7B shows a top view ofknuckle 700, FIG. 7C shows a cross-sectional view of knuckle 700 alongan x-y plane, FIG. 7D shows a side view of knuckle 700 from inside anelectronic device, and FIG. 7E shows a cross-sectional view of knuckle700 along a y-z plane.

Similar to knuckle 600 of FIGS. 6A-6E, knuckle 700 can include rib 710,rib 712, spine 714, dovetail 720, dovetail 730, dovetail 732, and middleportion 740. Also similar to knuckle 600 of FIGS. 6A-6E, knuckle 700 caninclude surfaces 750, 760, and 770 that can be substantially flush witha surface of the electronic device, thereby providing an aestheticallypleasing facade for the electronic device. However, dissimilar toknuckle 600, the corners of dovetails 730 and 732 (FIG. 7D) can berelatively more rounded than dovetails 630 and 632 (FIG. 6D),respectively. Also dissimilar to knuckle 600, ribs 710 and 712 can berelatively enlarged, such that ribs 710 and 712 substantially form anoval shape together. For example, when viewing the cross-sectional viewof knuckle 700 in the y-z plane (FIG. 7E), ribs 710 and 712 can togetherextend substantially across the entire top length of knuckle 700. Such adesign may significantly increase the surface area of knuckle 700. This,in turn, can increase the capacitance of knuckle 700, thus providingincreased electrical isolation between sections coupled by knuckle 700.

In some embodiments, the electronic device can undergo impact testing toensure the knuckle has been designed with sufficient structuralstability and strength. For example, in some cases a “Mean Drops toFailure” test can be used. In a Mean Drops to Failure test, anelectronic device can be repeatedly dropped from a same height. Forexample, the electronic device can be repeatedly dropped from a heightof 1.2 meters. Several electronic devices can be repeatedly droppeduntil they finally fail (e.g., break). The mean number of drops requiredto fail the electronic device can then be determined, and compared tothreshold value. As an illustration, in order to pass the test, theelectronic devices must meet a threshold value of greater than 30 meansdrops to failure, or any other suitable threshold value. In someembodiments, the electronic device can be dropped while at 100% of itsweight (e.g., rather than adding weights to the electronic device, orremoving weight from the electronic device). Such testing methods maygive more accurate results than, for example, merely dropping anelectronic device a fixed number of times.

It should be understood that the processes described above are merelyillustrative. Any of the steps may be removed, modified, or combined,and any additional steps may be added or steps may be performed indifferent orders, without departing from the scope of the invention.

The described embodiments of the invention are presented for the purposeof illustration and not of limitation.

What is claimed is:
 1. A component of an electronic device, wherein thecomponent is substantially rectangular in cross-section and has at leastone spline, the component comprising: a first section constructed from afirst conductive material; a second section constructed from a secondconductive material; and a first knuckle constructed from an insulatingmaterial, wherein: the first knuckle is located in a first spline of thecomponent; and a first side of the first knuckle is connected to thefirst section and a second side of the first knuckle is connected to thesecond section, such that the first knuckle couples the first section tothe second section at the first spline.
 2. The component of claim 1,wherein the first knuckle includes a first rib feature and a second ribfeature, wherein the first rib feature locks the first knuckle into thefirst section and the second rib feature locks the first knuckle intothe second section.
 3. The component of claim 2, wherein each of thefirst rib feature and the second rib feature have a cylindrical shapethat extends along a height of the first knuckle.
 4. The component ofclaim 2, wherein the first knuckle further includes a first channel, asecond channel, and a middle portion, and wherein the first channelconnects the first rib feature to the middle portion and the secondchannel connects the second rib feature to the middle portion.
 5. Thecomponent of claim 4, wherein the middle portion of the first knucklehas an increased volume in areas of high strain to the first knuckle. 6.The component of claim 1, wherein the first knuckle includes ahorizontal dove tail and at least one vertical dove tail.
 7. Thecomponent of claim 1, wherein the first knuckle includes at least onelock feature coupling the knuckle to at least one of the first sectionand the second section.
 8. The component of claim 1, wherein the firstknuckle meets a minimum capacitance requirement.
 9. The component ofclaim 1, wherein the first knuckle meets a minimum surface arearequirement.
 10. The component of claim 1, wherein the knuckle includesa spine extending along an entire height of the knuckle.
 11. A methodfor constructing an electronic device component, the method comprising:providing a first section formed from a first material; providing asecond section formed from a second material; connecting the first andsecond sections together with a knuckle formed from a third material toform the electronic device component, wherein the electronic devicecomponent comprises at least one spline and wherein the first and secondsections connect together at the at least one spline.
 12. The method ofclaim 11, wherein connecting the first and second sections together witha knuckle comprises: prefabricating the knuckle from the third material;and snapping the knuckle into the first section and into the secondsection.
 13. The method of claim 11, wherein connecting the first andsecond sections together with a knuckle comprises: inserting the knucklein between the first and second section while the knuckle is in a firststate; and changing the knuckle from the first state into a secondstate.
 14. The method of claim 13, wherein: the first state is a liquidand the second state is a solid; the knuckle changes into the firststate by applying heat to the first section, to the second section, andto the knuckle; and the knuckle changes into the second state by coolingand hardening the knuckle.
 15. The method of claim 11, whereinconnecting the first and second sections together with a knucklecomprises using a molding process in which: the third material isinserted in a liquid state between the first section and the secondsection; and the third material is subsequently hardened into theknuckle.
 16. The method of claim 15, wherein the molding processcomprises one of injection molding, compression molding, transfermolding, extrusion molding, blow molding, thermoforming, vacuum forming,and rotomolding.
 17. The method of claim 11, wherein connecting thefirst and second sections together with a knuckle comprises using abrazing process in which: the third material is placed in a fixturebetween the first section and the second section; and the third materialis subsequently heated such that the third material melts and fills thefixture.
 18. The method of claim 17, wherein the brazing processcomprises one of torch blazing, furnace brazing, braze welding, vacuumbrazing, and dip brazing.
 19. The method of claim 17, wherein the thirdmaterial comprises a dielectric composite material.